Process for metalworking fluid from heavy alkylate

ABSTRACT

The process relates to composition of metalworking fluid and for its preparation based on heavy alkyl benzenes having 22 to 26 carbon atoms to replace mineral oil and process for the same. A process for heavy alkylate based less toxic metalworking fluid composition comprising of heavy alkyl benzene, one emulsifier which is a sodium oleate, sulfonate or mixtures thereof, a vegetable oil as lubricity booster, an antioxidant, a fungicide, an extreme pressure additive, an antirust, a co-surfactant, a coupling agent and alkali component. The process comprising of removing of insoluble matter from the heavy alkylate, addition of emulsifier, additives, coupling agent and co-surfactant, homogenizing the mixture at 20-120° C., followed by conditioning of the metal working fluid concentrate which can be used as emulsion in water.

FIELD OF INVENTION

The present invention relates to a process for metalworking fluids fromheavy alkylate. More particularly this invention relates to compositionof metalworking fluid and process for its preparation based on heavyalkyl benzenes having 22 to 26 carbon atoms to replace mineral oil.

BACKGROUND AND PRIOR ART REFERENCES

Traditionally, the mineral oils and petroleum sulfonates have been thebasic source of metalworking fluid formulations. The petroleum basedlubricating oils and sulfonates are hydrocarbons of varying compositionconsisting of naphthenes, paraffins and aromatics. The sulfonates on theother hand formed by sulfonation of aromatic components in theselubricating oil streams act as oil/water emulsifiers. Besides thesevarious additives, which are primarily chemicals of defined compositionor structure, are added to the soluble oils to improve thephysico-chemical properties and performance of metalworking fluids.Petroleum based soluble oils, generally suffer from many disadvantagessuch as higher toxicity to the environment, poor biodegradability andever-changing characteristics with changes in crude oil composition. Theother types of lubricants known as synthetic lubricants are designed foruse in extreme conditions of temperature, pressure, radiation orchemical environment and have excellent lubricity and thermal stability.The synthetic lubricants are relatively costly as compared to petroleumbased lubricants. Poly-glycols, polybutenes, dibasic acid esters,fluoropolymers, polyol esters, phosphate esters, silicones, poly-alphaolefins etc. are commonly used synthetic lubricants for variousapplications. Some of the synthetics are also toxic to environment andare not readily biodegradable. Similar disadvantages are found withPetroleum sulfonates which are by-products of sulfonation of lubricatingoils also suffer from inconsistent emulsification and compatibilitycharacteristics due to everchanging composition of the lubricating oils.

Keeping in the view the environmental concerns and improved performance,consistency in structural and performance characteristics, there is aneed to develop alternative lubricant and emulsifier component, formetalworking fluids, which are less toxic and low cost which showequivalent or improved performance to mineral oil or synthetic lubricantbased metalworking fluids.

The use of Heavy alkyl benzene as lubricant is very limited. Recently,the Heavy Alkyl Benzene alkaline earth metal sulfonates are in use asdetergent-dispersant-anti rust additive in various types of lubricants.

Reference may be made to M/S Petresa, Madrid, Spain, (www.petresa.es)wherein they are marketing heavy alkylate under the brand name of‘PETRENE’ to be use as thermal fluid, transformer oil, refrigeratingoil, sulfonation feedstock and lubricating greases but not formetalworking fluids.

Reference may be made to M/s Chevron, U.S.A. Inc., (San Ramon, Calif.)has U.S. Pat. No. 6,187,981 “Process for producing arylalkanes andarylalkanes sulfonates, compositions produced therefrom, and usesthereof”. Wherein this invention is a process for producingaryl-alkanes. This invention also provides process that to producemodified alkylbenzene sulfonates, which can be used as detergents.

Chevron, U.S.A. Inc., (San Ramon, Calif.) has U.S. Pat. No. 6,392,109“Synthesis of alkylbenzenes and synlubes from Fischer-Tropsch products”which is for an integrated process for producing alkylbenzenes,sulfonated alkylbenzenes and/or alkylcyclohexanes from syngas and usedas detergents and/or dispersants.

In view of the growing concern about the environment, there is a needfor less-toxic lubricant component for metalworking soluble oil based onHeavy alkyl benzene, which is a new application of the heavy alkylate.It will not only reduce the toxicity of soluble oil but also will bemore cost effective than mineral oil because of improved and consistentperformance because both the mineral oil component and the sulfonatesmade from these alkylates can be tailored to obtain a high performanceproduct of consistent quality. It is an additional benefit to thealkylate industry.

OBJECTS OF THE INVENTION

The main object of the present invention is to provide a process formetalworking fluids from heavy alkylate.

Another object of the present invention is to provide heavy alkylatebased less toxic lubricant component metalworking fluids.

Still another objects of the present invention is to provide a newapplication to the by-product heavy alkylate.

Yet another object of the present invention is to provide newcomposition of metalworking fluid for the benefit of metalworking andalkylate manufacturing industries.

SUMMARY OF INVENTION

The present invention relates to a process for metalworking fluids fromheavy alkylate. More particularly this invention relates to compositionof metalworking fluid and process for its preparation based on heavyalkyl benzenes having 22 to 26 carbon atoms to replace mineral oil.

The speed of machining could be greatly increased if the cutting surfaceis kept cool and lubricated. Water can be regarded as the first cuttingfluid because of its high specific and latent heats to give it uniquepotential cooling power and also it is available everywhere at low cost.However, due to poor wetting efficiency, water alone can't cool themetal surface with its full ability. Another serious disadvantage is theformation of rust on iron and steel surfaces. Modem development has ledto the introduction of advanced water-oil emulsion incorporating specialchemicals, which considerably improve its wettability, lubrication, highcooling power, rust inhibiting and detergency properties. Theseconcentrates and their emulsions in water are known as ‘Soluble Oil’.They are ideal for general machining process where Cooling, Lubrication,Cleaning and extreme pressure characteristics are essential requirements

DETAILED DESCRIPTION

Accordingly the present invention provides a process for metalworkingfluid from heavy alkylate, which comprises;

-   -   (a) residual fraction having C20 to C22 carbon atom of detergent        class Alkyl Benzene in the concentration range of 50 to 90        weight percent of the metal working fluid, (b) at least one        emulsifier in the range of 10 to 40 weight percent of the        metalworking fluid, (c) at least one lubricity booster component        in the concentration range of 2-10 percent of metal working        fluid, (d) an antioxidant component is in the concentration        range of 50-500 ppm, (e) a fungicide component in the        concentration range of 50-500 ppm, (f) an extreme pressure        additive component in the concentration range of 50-500 ppm (g)        an antirust component in the concentration range of 50-500        ppm, (h) a co-surfactant component in the range of 1-10 weight        percent of metal working fluid, (i) a coupling agent in the        range of 0.5 to 10 weight percent of metal working fluid, (j)        alkali component in the range of 8-10 weight percent of metal        working fluid.

Heavy alkyl benzene is produced as by-products during the preparation oflinear alkyl benzene sulfonates for detergent industry. The alkylationreaction of C₁₀-C₁₄ olefin with benzene results in side reactions togive dialkyl benzenes and alkylated condensed ring derivatives. Theseproducts are generally in the range of 5 to 15 percent of the totalalkylates depending upon the reaction conditions and purity of reactantsemployed. Heavy alkyl benzene consists of substituted benzenes andNaphthalenes as determined by HPLC, UV, IR and RI analysis given inTable- 1. The typical properties such as density, kinetic viscosity,viscosity index, refractive index, pour point, molecular weight anddistillation characteristics were given in Table- 2. No poly-aromaticsor olefinic compounds are present in the heavy alkylates. These heavyalkylates have been acquired from the Indian market. TABLE 1 TypicalRelative Content of Alkyl Benzenes and Alkyl Napthalenes HAB-I HAB-IIComponents IR UV 254 IR UV 254 Alkyl Benzenes % by wt. 84 ± 2 84 ± 2 93± 2 90 ± 2 Alkyl Napthalenes % by wt. 15 ± 2 16 ± 2  7 ± 2 10 ± 2

TABLE 2 Typical Characteristics of Heavy Alkyl Benzenes CharacteristicsHAB-I HAB-II Density at 15° C. 0.8839 0.8813 K. Viscosity Cst at 40° C.28.95 26.93 K. Viscosity Cst at 100° C. 4.50 4.31 Viscosity Index 37 32Pour Point ° C. (−) 27 (−) 25 Molecular wt. 365 ± 5  361 ± 5 Distillation range ° C. 225-440 226-515 (ASTM D1160) Refractive index at20° C. 1.4946 1.4916

In an embodiment of the present invention the oil component is a heavyalkyl benzene having C20-C22 carbon number, a heavy fraction,by-product, separated from detergent class alkyl benzene duringmanufacture.

In another embodiment of the present invention the concentration ofheavy alkyl benzene component is in between 50 to 90 weight percent ofthe metalworking fluid.

In yet another embodiment of the present invention the emulsifiercomponent is a heavy alkylate sodium sulfonates, sodium carboxylate,sodium oleate, Triethalonoamine oleate, Diethalonoamine oleate orDodecyl Toluene sodium sulfonate or mixtures thereof.

In still another embodiment of the present invention the concentrationof emulsifier component is in between 10 to 40 weight percent of themetalworking fluid.

In still another embodiment of the present invention the vegetable oilcomponent for lubricity booster is a karanja oil, neem oil, rice-branoil, castor oil or mixtures thereof.

In still another embodiment of the present invention the concentrationof vegetable oil component for lubricity boost is in between 2 to 10weight percent of the metalworking fluid.

In still another embodiment of the present invention the antioxidantcomponent is an alkyl phenol or aromatic amine or substituted alkylphenol selected from 2,6-ditertiary butyl phenol, 2,6-ditertiaryp-cresol, Diphenylamine, Tertiary butyl phenol amino tetrazole and2,6-dioctyl phenylene diamine.

In still another embodiment of the present invention the concentrationof antioxidant component is in between 50 to 500 ppm.

In still another embodiment of the present invention the fungicidecomponent is a phenol or phenolic acid selected from o-cresol, phenol,m-cresol and cresylic acid.

In still another embodiment of the present invention the concentrationof fungicide component is in between 50 to 500 ppm.

In still another embodiment of the present invention the extremepressure additive component is an organic sulfide or phosphosulfurizedmetal salt selected from dibenzyl disulphide, sulfurized vegetable oil,phosphosulfurized decyl oleate molybdate and phosphothio pentadecylphenol molybdate.

In still another embodiment of the present invention the concentrationof extreme pressure additive component is in between 50 to 500 ppm.

In still another embodiment of the present invention the anti-rustcomponent is a triazole or sulfonate selected from 1H-benzotriazole,ditertiary butylated 1H-Benzotriazole, calcium petroleum sulfonate andcalcium heavy alkylate sulfonate.

In still another embodiment of the present invention the concentrationof ant-rust component is in between 50 to 500 ppm.

In still another embodiment of the present invention the co-surfactantcomponent is a alcohol selected from isopropanol, n-butanol,iso-butanol, iso-amyl alcohol, 2 ethyl hexanol, mono & poly glycol suchas di ethylene glycol and tri ethylene glycol.

In still another embodiment of the present invention the concentrationof co-surfactant component is in between 1 to 10 weight percent of themetalworking fluid.

In still another embodiment of the present invention the coupling agentcomponent is a sulfonates (molecular weight less than 350) selected fromligno sulfonate, petroleum sulfonate, sodium dodecyl benzene sulfonateand sodium lauryl sulfate.

In still another embodiment of the present invention the concentrationof coupling agent component is in between 0.5 to 10 weight percent ofthe metalworking fluid.

In still another embodiment of the present invention the alkalicomponent is a alkali and alkaline earth metal salt selected from sodiumcarbonate, sodium hydrogen carbonate, calcium carbonate, calcium oxide.

In still another embodiment of the present invention the concentrationof alkali component is in between 0.5 to 8 weight percent of themetalworking fluid.

In still another embodiment of the present invention the composition issuitable for use as metal working fluid and general emulsion asadmixture with water in concentration ranging from 20 to 80 weightpercent.

After the addition of all the components the mixture is homogenized.Then it is conditioned by keeping it at room temperature for 24 hoursundisturbed. Dilute emulsion of the soluble oil may be prepared bymixing the concentrate in water with vigorous agitation for 1 to 5minutes in the ratio of 20:80 to 80:20 as per requirements of the metalwork and nature of metal.

It will be apparent from the foregoing that the present inventionprovides non-toxic lubricant component by using heavy alkyl benzene anduseful for making formulation for metalworking soluble oil. Thisinvention further provides a suitable new application for heavy alkylbenzene as a by-product to increase its value.

The invention will now be further described by the following examples,which are given only for the purpose of illustration and not intended tolimit the scope of the invention.

Although the invention has been described in conjunction with examplesand by reference to the embodiments thereof, it is evident that manyalternatives, modifications and variations will be apparent to thoseskilled in art in light of the foregoing description, accordingly it isintended in the invention to embrace these and all such alternatives,variations and modifications as may fall with in the sprit and scope ofthe appended claims.

EXAMPLE-1

After removal of insoluble matter, the heavy alkyl benzene in 65 weightpercent was mixed with heavy alkyl benzene sodium sulfonate in 10 weightpercent and karanja oil 5 weight percent of metalworking fluid ascomponent for lubricity. The mixture was homogenized at 30 to 100° C.for one hour with stirring to obtain clear solution. Then lignosulfonate as coupling agent in concentration of 5 weight percent of thefluid, 2,6, ditertiary butyl 4 methyl phenol 100 ppm as antioxidant,cresylic acid 100 ppm as fungicide, dibenzyl disulfide 100 ppm asextreme pressure additive, 1H-benzotriazole 100 ppm as antirust additiveand isobutanol 5 weight percent of the metalworking fluid asco-surfactant were added. The mixture was further homogenized for 30minutes. Water was added to make-up quantity to 1 kg and furtherhomogenized for 30 minutes. The pH of the solution was adjusted to 7-9by adding sodium carbonate. The solution was cooled down to roomtemperature with stirring. The final composition (HA-1) is given inTable-3. The neat soluble oil then mixed with water in 60:40 ratio andshaken to produce oil-water emulsion. This emulsion was evaluated forits different characteristics, which are given in Table-4 and 5. It wasfound that the characteristics of the neat and emulsion are at par withthe specifications. TABLE 3 TYPICAL COMPOSITION OF SOLUBLE OIL SNConstituents HA-I HA-II HA-III 1 Heavy Alkyl 65 60 75 Benzene % 2Emulsifier % 10 15 10 3 Additives ppm 400 350 450 4 Co-surfactant 6 5 7% 5 Lubricity 5 5 5 Additive 6 Coupling 4 6 3 agent % 7 Alkali % 1approx. 1 approx. 1 approx. 8 Water % 5-10 approx. 5-10 approx. 5-10approx.

EXAMPLE-2

The procedure of Example 1 was repeated with alkylate 60 weight percentexcept that Dodecyl Toluene Sodium Sulfonate 15 weight percent was takenas emulsifier in place of Heavy Alkyl Benzene Sodium Sulfonate, neem oilas component for lubricity in place of Karanja oil, 2,6-dioctylphenylene diamine as antioxidant in place of 2,6,-ditertiary butyl4-methyl phenol, m-cresol as fungicide in place of cresylic acid,phosphothio pentadecyl phenol as extreme pressure additive in place ofdibenzyl disulphide. The final composition (HA-I1) is given in Table-3and evaluation in Table-4 & 5.

EXAMPLE-3

The procedure of Example 1 was repeated with alkylate 75 weight percentexcept that Sodium Oleate 10 weight percent was taken as emulsifier inplace of Heavy Alkyl Benzene Sodium Sulfonate. The final composition(HA-II1) is given in Table-3 and evaluation in Table-4 & 5. It was foundthat the characteristics of the neat and emulsion are as perrequirement. TABLE 4 TYPICAL CHARACTERISTICS OF SOLUBLE OIL TotalReactable K. Viscosity Acid No- Flash Sulfur at SN Formulation 40° C. -Cst mg KOH Ash % Clarity Point-° C. 100° C. 1 HA-I 23.3 NIL 0.009 Clear210 NIL 2 HA-II 26.2 NIL 0.008 Clear 215 NIL 3 HA-III 24.5 NIL 0.006Clear 213 NIL

TABLE 5 TYPICAL EVALUATION OF SOLUBLE OIL Saponification Copper DepositEmulsion Cast value - Low temp Frothing SN Formulation corrosion teststability iron rust mg KOH Stability Test 1 HA-I <1 NIL Pass Pass 4.8Pass Pass 2 HA-II <1 NIL Pass Pass 4.5 Pass Pass 3 HA-III <1 NIL PassPass 4.6 Pass Pass

1. A metalworking fluid from heavy alkylate, comprising; (b) residualfraction having C20 to C22 carbon atom of detergent class Alkyl Benzenein the concentration range of 50 to 90 weight percent of the metalworking fluid, (b) at least one emulsifier in the range of 10 to 40weight percent of the metalworking fluid, (c) at least one lubricitybooster component in the concentration range of 2-10 percent of metalworking fluid, (d) an antioxidant component is in the concentrationrange of 50-500 ppm, (e) a fungicide component in the concentrationrange of 50-500 ppm, (f) an extreme pressure additive component in theconcentration range of 50-500 ppm (g) an antirust component in theconcentration range of 50-500 ppm, (h) a co-surfactant component in therange of 1-10 weight percent of metal working fluid, (i) a couplingagent in the range of 0.5 to 10 weight percent of metal working fluid,(j) alkali component in the range of 8-10 weight percent of metalworking fluid.
 2. A composition as claimed in claim 1, wherein theresidual component of Alkyl Benzene is a oil component having heavyalkyl benzene of C20-C22 carbon number, a heavy fraction by-productseparated from detergent class alkyl benzene during manufacture.
 3. Acomposition as claimed in claim 1, wherein the emulsifier is selectedfrom the group consisting of heavy alkylate sodium sulfonates, sodiumcarboxylate, sodium oleate, Triethalonoamine oleate, Diethalonoamineoleate or Dodecyl Toluene sodium sulfonate or mixtures thereof.
 4. Acomposition as claimed in claim 1, wherein the lubricity booster is avegetable oil selected from the group consisting of karanja oil, neemoil, rice-bran oil, castor oil or mixtures thereof.
 5. A composition asclaimed in claim 1, wherein the antioxidant component is selected fromthe group consisting of an alkyl phenol, aromatic amine, substitutedalkyl phenol selected from 2,6-ditertiary butyl phenol, 2,6-ditertiaryp-cresol, Diphenylamine, Tertiary butyl phenol amino tetrazole and2,6-dioctyl phenylene diamine.
 6. A composition as claimed in claim 1,wherein the fungicide component is a phenol or phenolic acid selectedfrom the group consisting of o-cresol, phenol, m-cresol and cresylicacid.
 7. A composition as claimed in claim 1, wherein the extremepressure additive component is an organic sulfide or phosphosulfurizedmetal salt selected from the group consisting of dibenzyl disulphide,sulfurized vegetable oil, phosphosulfurized decyl oleate molybdate andphosphothio pentadecyl phenol molybdate.
 8. A composition as claimed inclaim 1, wherein the anti-rust component is a triazole or sulfonateselected from the group consisting of 1H-benzotriazole, ditertiarybutylated 1H-Benzotriazole, calcium petroleum sulfonate and calciumheavy alkylate sulfonate.
 9. A composition as claimed in claim 1,wherein the co-surfactant component is a alcohol selected from the groupconsisting of isopropanol, n-butanol, iso-butanol, iso-amyl alcohol, 2ethyl hexanol, mono & poly glycol such as di ethylene glycol and triethylene glycol.
 10. A composition as claimed in claim 1, wherein thecoupling agent component is a sulfonates (molecular weight less than350) selected from the group consisting of ligno sulfonate, petroleumsulfonate, sodium dodecyl benzene sulfonate and sodium lauryl sulfate.11. A composition as claimed in claim 1, wherein the alkali component isa alkali and alkaline earth metal salt selected from the groupconsisting of sodium carbonate, sodium hydrogen carbonate, calciumcarbonate and calcium oxide.
 12. A composition as claimed in claim 1,wherein the composition is suitable for use as metal working fluid andgeneral emulsion as admixture with water in concentration range from 20to 80 weight percent.
 13. A process for preparing metalworking fluid asclaimed in claim 1, said process comprises the steps of; a. removing ofinsoluble matter from the heavy alkylate followed by addition ofemulsifier and vegetable oil to obtain the mixture; b. homozenising theresultant mixture at a temperature in the range of 30 to 100° C. forabout one hour with stirring; c. adding the antioxidant, fungicide,extreme pressure additives, anti trust component, cosurfactant, couplingagent, alkali, followed by addition of water to make up the quantityabout 1 kg, and d. homogenizing the mixture for about 30 minutes, the pHof the solution was adjusted to 7-9 by addition of sodium carbonate andcooling the resultant metal working fluid at room temperature.
 14. Aprocess as claimed in claim 13, wherein the residual component of AlkylBenzene is a oil component having heavy alkyl benzene of C20-C22 carbonnumber, a heavy fraction, by-product, separated from detergent classalkyl benzene during manufacture.
 15. A process as claimed in claim 13,wherein the concentration of heavy alkyl benzene component is in therange of 50 to 90 weight percent of the metalworking fluid.
 16. Aprocess as claimed in claim 13, wherein the emulsifier is selected fromthe group consisting of heavy alkylate sodium sulfonates, sodiumcarboxylate, sodium oleate, Triethalonoamine oleate, Diethalonoamineoleate or Dodecyl Toluene sodium sulfonate or mixtures thereof.
 17. Aprocess as claimed in claim 13, wherein the concentration of emulsifiercomponent is in the range of 10 to 40 weight percent of the metalworkingfluid.
 18. A process as claimed in claim 13, wherein the vegetable oilcomponent for lubricity booster is selected from the group consisting ofkaranja oil, neem oil, rice-bran oil, castor oil or mixtures thereof.19. A process as claimed in claim 13, wherein the concentration ofvegetable oil component for lubricity boost is in the range of 2 to 10weight percent of the metalworking fluid.
 20. A process as claimed inclaim 13, wherein the antioxidant component is selected from the groupconsisting of an alkyl phenol, aromatic amine, substituted alkyl phenolselected from 2,6-ditertiary butyl phenol, 2,6-ditertiary p-cresol,Diphenylamine, Tertiary butyl phenol amino tetrazole and 2,6-dioctylphenylene diamine.
 21. A process as claimed in claim 13, wherein theconcentration of antioxidant component is in the range of 50 to 500 ppm.22. A process as claimed in claim 13, wherein the fungicide component isa phenol or phenolic acid selected from the group consisting ofo-cresol, phenol, m-cresol and cresylic acid.
 23. A process as claimedin claim 13, wherein the concentration of fungicide component is in therange of 50 to 500 ppm.
 24. A process as claimed in claim 13, whereinthe extreme pressure additive component is an organic sulfide orphosphosulfurized metal salt selected from the group consisting ofdibenzyl disulphide, sulfurized vegetable oil, phosphosulfurized decyloleate molybdate and phosphothio pentadecyl phenol molybdate.
 25. Aprocess as claimed in claim 13, wherein the concentration of extremepressure additive component is in the range of 50 to 500 ppm.
 26. Aprocess as claimed in claim 13, wherein the anti-rust component is atriazole or sulfonate selected from the group consisting of1H-benzotriazole, ditertiary butylated 1H-Benzotriazole, calciumpetroleum sulfonate and calcium heavy alkylate sulfonate.
 27. A processas claimed in claim 13, wherein the concentration of ant-rust componentis in the range of 50 to 500 ppm.
 28. A process as claimed in claim 13,wherein the co-surfactant component is a alcohol selected from the groupconsisting of isopropanol, n-butanol, iso-butanol, iso-amyl alcohol, 2ethyl hexanol, mono & poly glycol such as di ethylene glycol and triethylene glycol.
 29. A process as claimed in claim 13, wherein theconcentration of co-surfactant component is in the range of 1 to 10weight percent of the metalworking fluid.
 30. A process as claimed inclaim 13, wherein the coupling agent component is a sulfonates(molecular weight less than 350) selected from the group consisting ofligno sulfonate, petroleum sulfonate, sodium dodecyl benzene sulfonateand sodium lauryl sulfate.
 31. A process as claimed in claim 13, whereinthe concentration of coupling agent component is in the range of 0.5 to10 weight percent of the metalworking fluid.
 32. A process as claimed inclaim 13, wherein the alkali component is a alkali and alkaline earthmetal salt selected from the group consisting of sodium carbonate,sodium hydrogen carbonate, calcium carbonate, calcium oxide.
 33. Aprocess as claimed in claim 13, wherein the concentration of alkalicomponent is in the range of 0.5 to 8 weight percent of the metalworkingfluid.